2004 Mitsubishi Lancer Problems

What owners report

Owners of the 2004 Lancer most often report a climate-control temperature knob that becomes stiff and then breaks, leaving no heat or defrost, along with air bag warning lights and delays or difficulties getting the passenger-side inflator recall done. Other recurring reports include occasional unintended acceleration or sudden power loss, a cooling fan that runs on and drains the battery, and corroded front suspension or crossmember hardware.

1. 1
   Visibility (wipers, defrost, mirrors)

   Heater/AC temperature knob sticks and breaks, no defrost

   • 22 complaints (28%)
   • median 67,050 mi at 5.6 yrs old (16 state mileage)
   • owner-quoted repair $1,000 (median of 8 quotes)
   • filed 2007–2015

   Complaints describe the dashboard temperature knob becoming progressively harder to turn from cold to heat and eventually breaking off, sometimes taking part of the shaft with it. Owners then have no heat and no windshield defrost; some adjust the blend door with pliers or reach under the dash, and several mention quoted repair costs ranging from roughly $300 to over $1,600 because the dash has to be partly disassembled. Dealers are described as recognizing the problem, and some complaints note a service bulletin covers this symptom; several owners say they were told the car was out of warranty or that it was not treated as a safety matter. Reported from low mileage up through roughly 170,000 miles, with many cases in the 20,000-100,000 mile range and symptoms noticed more in cold or rainy weather when defrost is needed.

   What to check: Turn the temperature knob slowly through its full range and feel for stiffness or binding, and confirm the blower and defrost work on every setting. Ask whether the heater control unit or blend door lever has ever been replaced, and what that cost.

   2 excerpts from owner complaints in NHTSA records

   “The air and heat flow knob broke off as I turned it from cold to heat this morning. Now I cant heat up the car it is stuck on cold. Due to this the defrost will not work either. I have no heat in my car as of this morning due to the knob breaking off as I turned it. Part of the white plastic piece that attaches on the inside is now attached to the knob that broke off.”

   NHTSA complaint #10475003, filed 2012-09, 129,000 miles

   “This is with reference to the climate control panel, the knob to turn system temperature from cold to heat, with time the knob got stiff and it was very hard to turn from cold to heat, for years I have had to play with it every time I needed to use it to switch to the temperature I desired according to the weather, especially in the rain and when going from summer to winter. …”

   NHTSA complaint #10683948, filed 2015-02, 20,000 miles
2. 2
   Air bags

   Air bag warning light on and recall repairs hard to get

   • 18 complaints (23%)
   • median 65,000 mi at 12.6 yrs old (6 state mileage, few)
   • 2 mention a crash, fire or injury
   • filed 2005–2019

   Many complaints concern the passenger frontal air bag inflator recalls: owners describe long waits for parts, dealers or repair shops far from home, and trouble scheduling or getting a response. Others report the air bag warning light staying on, including after a recall repair, and a few describe an air bag deploying without a crash or failing to deploy in a collision. Recall mailings and dealer follow-up are described as inconsistent. Raised across a wide mileage span, from vehicles at low mileage to ones past 150,000 miles, and often years after the original purchase as recall notices arrived.

   Recall 17V569000Recall 18V2200004 related service bulletins

   What to check: Check whether the passenger-side inflator recalls (17V569 and 18V220) were completed, and ask for paperwork. With the key on, confirm the air bag warning light comes on and then goes out.

   2 excerpts from owner complaints in NHTSA records

   “Recall on takata inflators. There is no Mitsubishi dealer in rochester, mn. I am 95 years old and cannot drive out of rochester, mn. What should I do to get the inflator replaced?”

   NHTSA complaint #11042094, filed 2017-11, 45,000 miles

   “Dear administrator: there has been no accident....I am following instruction from letter. I recently received a letter notifying me of a safety recall regarding the passenger air bag inflater housing for 2004-2005 Mitsubishi Lancer vehicles. I currently still own a 2004 Lancer Mitsubishi and I am extremely concerned for the safety of any front seat occupants. Therefore, I immediately responded to the letter from Mitsubishi and followed your instructions. Unfortunately, the response that I received was shocking and quite frankly, ridiculous! …”

   NHTSA complaint #10667830, filed 2014-12
3. 3
   Vehicle speed control

   Unintended acceleration, surging, or sudden power loss

   • 8 complaints (10%)
   • median 34,000 mi at 2.2 yrs old (7 state mileage, few)
   • filed 2005–2012

   Complaints describe the engine speeding up on its own, sometimes while cruising with cruise control engaged and sometimes while braking for a stop or off-ramp. Others report the opposite: the car abruptly loses power and will not rev past about 2,500 rpm, which owners link to the accelerator pedal position sensor; in some cases the sensor was replaced repeatedly. Dealers are described as replacing the sensor or being unable to find a cause. Mostly reported at low mileage, often under 45,000 miles, and some owners say it happened repeatedly over months or years.

   What to check: Ask whether the accelerator pedal position sensor or throttle-related parts have been replaced and whether any stored codes were found. During a test drive, note any surging, hesitation, or a point where the engine stops pulling.

   2 excerpts from owner complaints in NHTSA records

   “Whenever driving, my vehicle suddenly stops accelerating over 2500 RPM's. When on the highway, it causes my car to drastically slow down, and I am forced to quickly move to the side of the road to avoid a collision. Dealer has replaced the app sensor on the vehicle twice already within several months, and is currently replacing it a third time. Very dangerous when on the highway.”

   NHTSA complaint #10158811, filed 2006-06, 30,708 miles

   “When using cruise control vehicle will sometimes surge ahead and speed up, although driving conditions do not require additional speed or power. This has happened to me on a daily basis since I have owned my car. This sudden increase in acceleration could easily cause an accident.”

   NHTSA complaint #10141982, filed 2005-11, 76 miles
4. 4
   Suspension

   Corroded front control arm and crossmember hardware

   • 6 complaints (8%)
   • median 151,199 mi at 13.5 yrs old (4 state mileage, few)
   • 1 mention a crash, fire or injury
   • filed 2016–2018

   Complaints describe the front control arm bolt seizing or breaking free from corrosion in the crossmember, making the arm impossible to remove without cutting into the frame, and one owner reports the subframe, control arm, and tie rod being replaced after the car stopped on railroad tracks. Others report a metal noise from the front suspension, pulling to one side, and uneven tire wear, with one owner told the crossmember needed replacement. Some owners say they were told their car was outside the scope of a corrosion-related suspension recall. Mostly reported above 80,000 miles, with several cases between about 145,000 and 182,000 miles.

   Recall 16V458000

   What to check: Have the front subframe, lower control arms, and their bolts inspected for rust, especially on cars from states that use road salt, and ask whether recall 16V458 was performed.

   2 excerpts from owner complaints in NHTSA records

   “I was going to replace the front control arms on my own but now I am only going to be able to replace the front passenger control arm because the driver side control arm is corroded and the bolt does not come out. I was going to buy the crossmember myself but than a family member showed me a link that says this crossmember on my model could be a recall. …”

   NHTSA complaint #11112984, filed 2018-07, 154,398 miles

   “Front internal bolt on k frame for the front a arm bolt broke free know way to fix this with out cutting a hole into the k frame . Did this going down the road .”

   NHTSA complaint #10928679, filed 2016-11, 182,000 miles

Buying note. Check the climate control knob and defrost function carefully and confirm the passenger air bag inflator recalls were completed with paperwork. Have the front suspension and subframe inspected for corrosion, and ask about any history of accelerator sensor or cooling fan problems before buying.

Summary written with AI from a sample of 60 NHTSA complaints for this model year (picked at random, with complaints that state a mileage and recent ones taken first), then checked automatically against the source records. Where a problem shows a complaint count, every complaint for this model year was matched with fixed keyword rules (written with AI and tested against the sample), and the mileage, age and repair figures are calculated from those complaints; owners' figures are as stated, not verified. Other counts refer to the sample. The excerpts come from NHTSA's public complaint records and are unverified; capitalisation is normalised, NHTSA staff notes are removed, and shortened text ends with “…”. Something wrong? Request a correction.